System for mounting objects to polymeric membranes

ABSTRACT

A system and method to attach an object to a support structure, the system including a fastener having an anti-rotational member, a mounting plate having a raised portion adapted to receive the fastener, and an elastic membrane. The fastener is sandwiched between the mounting plate and the elastic membrane. The raised portion forms a cavity having an inner surface. The inner surface abuts against the surfaces of the fastener, which in turn restricts movement.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. application Ser. No.12/559,117, filed 14 Sep. 2009 now U.S. Pat. No. 7,935,202, titled“System for Mounting Objects to Polymeric Membranes,” and is acontinuation-in-part of International Application No. PCT/US10/48734,filed 14 Sep. 2010, titled “System for Mounting Objects to PolymericMembranes,” which claims the benefit of U.S. application Ser. No.12/559,117, filed 14 Sep. 2009, titled “System for Mounting Objects toPolymeric Membranes;” both of which are both hereby incorporated byreference for all purposes as if fully set forth herein.

BACKGROUND

1. Field of the Present Description

The present description relates to methods and system for mountingobjects to polymeric membranes.

2. Description of Related Art

Various applications exist in which a polymeric membrane may be placedover a surface. For example, it may be desirable to provide a polymericmembrane as a roofing material. That is, a polymeric membrane may beapplied to an outer surface of a building structure, such as a roof, toprotect the structure from the environment.

DESCRIPTION OF THE DRAWINGS

The novel features believed characteristic of the invention are setforth in the appended claims. However, the invention itself, as well asa preferred mode of use, and further objectives and advantages thereof,will best be understood by reference to the following detaileddescription when read in conjunction with the accompanying drawings,wherein:

FIGS. 1A-1C show an example systems for attaching a mounting plate to apolymeric membrane;

FIG. 1D shows a cross-sectional view of an example mounting plate;

FIG. 2A is a cross-sectional view of an example mounting systemincluding a mounting plate secured to polymeric membrane with anadhesive;

FIG. 2B shows an exploded view in cross section of an example mountingsystem with a tape including adhesive on opposing sides thereof;

FIG. 2C shows a cross-sectional view of a further example mountingsystem.

FIG. 3 shows an example mounting assembly that may be coupled to apolymeric membrane;

FIG. 4 shows another example mounting assembly that may be coupled to apolymeric membrane;

FIG. 5 is a bottom view of the mounting assembly shown in FIG. 4;

FIGS. 6A-F, 7A-E, and 8A-D show various views of example mountingplates;

FIG. 9 shows a cross-sectional view of a further example mountingsystem;

FIG. 10 shows a cross-sectional view of an example mounting plateillustrated in FIG. 9;

FIG. 11 shows another example mounting system;

FIG. 12 is a side view of an example mounting plate shown in FIG. 11;

FIG. 13 is a further example mounting system that includes, among otherfeatures, an insulating member;

FIG. 14 is an example system for bonding a ridge member to a polymericmembrane;

FIG. 15 is an oblique view of a mounting system according to thepreferred embodiment of the present invention;

FIG. 16 is an oblique view of a mounting system of FIG. 15 shownattached to a support structure;

FIG. 17 is a front view of the mounting system of FIG. 15;

FIG. 18 is an exploded front view of the mounting system of FIG. 15;

FIG. 19 is a bottom view of a membrane of the mounting system of FIG.15;

FIG. 20A-20C are front views of the mounting system of FIG. 15 shown asa force is exerted on an object attached to the mounting system;

FIG. 21 is a top view of a mounting plate according to the preferredembodiment of the present invention;

FIG. 22 is a side cross-sectional view of the mounting plate of FIG. 21taken at XXII-XXII;

FIG. 23 is a side view of the mounting plate of FIG. 22 shown attachedto the mounting system of FIG. 17;

FIG. 24 is a front view of an alternative embodiment of the mountingplate of FIG. 21

FIG. 25 is an oblique view of a riser according to the preferredembodiment of the present invention;

FIG. 26 is a cross-sectional front view of the riser of FIG. 25 taken atXXVI-XXVI;

FIG. 27 is a front view of the riser of FIG. 25 shown attached to themounting assembly of FIG. 4;

FIG. 28 is an oblique view of a riser according to an alternativeembodiment of the present invention;

FIG. 29 is a cross-sectional front view of the riser of FIG. 28 taken atXXIX-XXIX;

FIG. 30 is an oblique view of a riser according to an alternativeembodiment of the present invention;

FIG. 31 is a cross-sectional side view of the riser of FIG. 30 taken atXXXI-XXXI;

FIG. 32 is an oblique view of a riser according to an alternativeembodiment of the present invention;

FIG. 33 is an oblique view of an alternative embodiment of a mountingplate;

FIG. 34 is a cross-sectional view of a portion of the mounting plate ofFIG. 33 taken at XXXIV-XXXIV;

FIG. 35 is an oblique view of a fastener;

FIG. 36 is an oblique view of an alternative embodiment of the fastenerof FIG. 35;

FIGS. 37 and 38 are cross-sectional views of an alternative embodimentof the fastener of FIG. 35;

FIG. 39 is an oblique view of an alternative embodiment of the mountingplate of FIG. 33;

FIG. 40 is a cross-sectional view of mounting plate of FIG. 39 taken atXL-XL;

FIG. 41 is a flow chart depicting the preferred method of assembling themounting system according to the preferred embodiment of the presentapplication;

FIG. 42 is a flow chart depicting the preferred method of assembling themounting plate of FIG. 33;

FIG. 43 is a front view of an alternative embodiment of the mountingsystem of FIG. 18;

FIG. 44 is the assembled embodiment of the mounting system of FIG. 43;

FIG. 45 is an oblique exploded view of an alternative embodiment of themounting system;

FIG. 46 shows an assembled oblique view of mounting system of FIG. 45;

FIG. 47 shows a cross-sectional front view of the mounting system ofFIG. 45 during operation; and

FIG. 48 shows a front view of the mounting system of FIG. 45 duringoperation and without a bracket; and

While the mounting system of the present application is susceptible tovarious modifications and alternative forms, specific embodimentsthereof have been shown by way of example in the drawings and are hereindescribed in detail. It should be understood, however, that thedescription herein of specific embodiments is not intended to limit theinvention to the particular embodiment disclosed, but on the contrary,the intention is to cover all modifications, equivalents, andalternatives falling within the spirit and scope of the process of thepresent application as defined by the appended claims.

DETAILED DESCRIPTION

The present disclosure describes methods and systems for mounting orotherwise attaching an object to polymeric membranes. For example, insome instances, the present disclosure describes methods and systems forattaching objects to polymeric membranes utilized for covering all or aportion of a building structure roof. In some instances, the polymericmembranes may include thermoplastic polymeric membranes (“thermoplasticmembranes”), while, in other instances, the polymeric membranes mayinclude thermoset polymeric membranes (“thermoset membranes”). Exampleobjects that may be attached include photovoltaic cells, an air handlingcomponent (e.g., air conditioning or heating components),telecommunications equipment (e.g., antennas, satellite dishes, etc.),or any other desired object. It should be understood that the materialsdescribed herein provide sufficient elasticity for the featuresdescribed below.

Utilizing the described systems and methods for securing one or morephotovoltaic cells to the roof of a structure may provide tax benefits.For example, tax benefits may exist for having photovoltaic cellsattached to the structure of a roof that are otherwise unavailable forphotovoltaic cells that are merely placed on a roof unattached to theroof structure. Thus, in some implementations, the system and methodsdescribed herein provide for attaching an object to the roof structure,and, in the case of photovoltaic cells, may enable a user to enjoy theavailable tax benefits associated therewith.

In other implementations, the described methods and systems may beutilized for attaching objects to a polymeric membrane forming part of astructure. Further, while some implementations may be described withrespect to thermoplastic membranes, thermoset membranes may also beapplicable and vice versa. In general, the described methods and systemsmay be applicable to applications including roofing, waterproofing,earth lining, pond lining, tent construction, tension fabricapplications, air forming technologies, flexible plastic forming (suchas with flexible plastic films), rigid plastic forms, as well as anyother suitable application.

FIG. 1A shows a perspective view of an example implementation of asystem for mounting an object to a polymeric membrane. FIG. 1A shows apolymeric membrane (interchangeably referred to as “membrane”) 10 and amounting plate 20. In some instances, the polymeric membrane 10 is athermoplastic membrane. Example thermoplastic membranes may includepolyvinyl chloride (PVC), thermoplastic olefins (TPO), keytone ethyleneesters (KEE), nitrile butadiene polymers (NBP), as well as othersuitable thermoplastics. In other instances, thermoset membranes mayalso be used. For example, examples thermoset membranes may includemembranes formed from ethylene propylene diene monomer (EPDM) as well asany other suitable thermoset membranes, including thermoplasticmembranes that may morph into thermoset membranes over time, such aschlorosulfonated polyethylene (CSPE).

The polymeric membrane 10 may be secured to a structure 40, such as aroof structure. The polymeric membrane 10 may be secured to thestructure 40 in any known or suitable manner. Further, in someinstances, the mounting plate 20 may be formed entirely or in part froma metal, such as steel, galvanized steel, aluminum, titanium, or otherdesired or suitable metal. Additionally, the mounting plate 20 may ormay not be weatherized. In other instances, the mounting plate 20 may beformed from other materials, such as glass, plastic, ceramics, compositematerials, or any other material. It should be appreciated that someapplications may not require polymeric membrane 10; as such, mountingplate 20 may be bonded or attached directly to structure 40 without theuse of polymeric membrane 10.

As shown, the mounting plate 20 has a protrusion 30 extending therefromthat may be used for securing a structure. The protrusion 30 may allowattachment and detachment of the structure, such as structure 35,without damage or alteration to the polymeric membrane 10. For example,in some instances, the protrusion 30 may provide for a threadedconnection with structure 35, although any other suitable connectionmechanism may be used. In other implementations, the mounting plate 20may be integral to a structure. In still other implementations, themounting plate 20 may omit the protrusion 30. Alternately, the mountingplate 20 may include a mechanism for attaching or detaching acorresponding structure thereto. For example, the mounting plate 20 mayinclude an interlocking mechanism for accepting one or more structures.Example structures may include one or more photovoltaic cells, airhandling equipment (e.g., air conditioning equipment or heatingequipment), one or more antennas, mounting structures therefor, abarrier, or any other desired structure.

In still other implementations, an example mounting plate 20 may includea threaded portion for mating engaging with a corresponding threadedportion provided on a structure to be attached or otherwise coupled tothe mounting plate 20. For example, FIG. 1B shows a mounting plate 20that includes a welded nut 22 for accepting a protrusion having matingthreads. Alternately, as shown in FIG. 1C, the mounting plate 20 mayhave a threaded portion 24 formed therein for accepting the protrusion.

FIG. 1D shows a cross-sectional view of another example mounting plate20 in which the protrusion 30 is a separate piece insertable into anopening 32 formed in the mounting plate 20. Further, a head 34 of theprotrusion 30 may be retained in a pocket 36 formed in the mountingplate 20. In other instances, the head 34 may not be retained in apocket formed in the mounting plate 20. In some implementations, theprotrusion 30 may be a carriage bolt insertable into the opening 32, andthe interface between the opening 32 and the protrusion 30 prevents theprotrusion 30 from rotating relative to the mounting plate 20. Further,a mounting plate 20 having an opening 32 of a single size may beoperable to accept protrusions 30 having varying shaft lengths, widths,and/or diameters.

The mounting plate 20 may be attached to the polymeric membrane 10 innumerous ways. FIGS. 2A-2C show several cross sectional views of themounting plate 20 attached to the polymeric membrane 10. For example,FIG. 2A shows the mounting plate 20 attached to the membrane 10 with abinding agent, such as an adhesive 50, disposed therebetween.Alternately, the binding agent for securing the mounting plate 20 may bea carrier tape 60 having adhesive 70, 80 provided on opposing sidesthereof, as shown in FIG. 2B. In some implementations, the carrier tape60 may have a removable protective film or backing 65. In some instancesthe adhesive 70 and adhesive 80 may be the same adhesive, while, inother instances, the adhesives 70, 80 may be different. For example,adhesives 70, 80 may be selected based on the material being adhered.For example, for a mounting plate 20 formed from steel, the adhesive 70may be selected to adhere steel, while, for a membrane 10 formed fromPVC, the adhesive 80 may be selected to adhere to PVC. In some instancesthe carrier tape 60 may be a foam-based tape. Carrier tape 60 may beused to secure the mounting plate 20 to the membrane 10. One or moretape strips or sheets may be used to secure the mounting plate 20.Further, the carrier tape 60 may be custom shaped and/or formed to fitto geometry of the mounting plate 20. For example, the carrier tape 60may be custom fit to correspond to one or more geometric features of themounting plate 20, such as protrusions or other topographical shapes.

Multiple options for adhesives 50, 70, and 80 are available andselecting an appropriate adhesive is often dependent upon the desiredengineered failure during testing. In some instances, it may bedesirable for the adhesion provided by the selected adhesive to give wayat a chosen weight threshold preventing damage to other componentswithin the assembly. In other instances, it may be desirable for theadhesive bond to be so strong that components would not separate withoutdamage to one surface or another. In addition, the selected adhesive maybe applied to a carrier tape, the carrier tape and selected adhesivealso being capable of being engineered with a chosen weight thresholdand thickness. Adhesives 50, 60, and 70 include cross linking as well asnon-cross linked butyl adhesives. A non-exclusive list of adhesives 50,70, and 80, as well as carrier tapes 60, that may be used are: 3M VHB4941 F, 3M VHB 4941, 3M VHB 4932, 3M VHB 4952, 3M VHB 5925, 3M VHB 5952,3M VHB 5962, 3M weather strip tapes, 3M Polyurethane 560, 3M HybridSealant 760, 3M DP 190, 3M DP 125, and 3M 1099 Scotch Weld Adhesive, allof which are produced by 3M of 3M Center, St. Paul, Minn. 55144.Additionally, Ashland Aroset 1930 produced by Ashland Inc of Covington,Ky. 41012 is another example of a suitable adhesive. Further,SikaLastomer-68 produced by Sika Corporation of Madison Heights, Mich.48071, is example of a suitable carrier tape. The following companiesmake similar or competing adhesive to those named above: Carlisle Syntecof Carlisle, Pa., Carlisle Hardcast Incorporated of Wylie, Tex., andFirestone Building Products of Indianapolis, Ind. It should beappreciated that the adhesives and carrier tapes identified above may beidentified as adhesives alone, or as carrier tape alone, or anycombination of carrier tape and adhesive.

FIG. 2C shows another example implementation in which the binding agentmay be a coating of thermoplastic material 90 applied to one or moresurfaces of the mounting plate 20 placed into contact with the polymericmembrane 10. For example, the polymeric membrane 10 may be athermoplastic membrane. The mounting plate 20 may be located at adesired location on the polymeric membrane 10, and the coating 90 may beheated to form a bond between the mounting plate 20 and the polymericmembrane 10. In some instances, the coating 90 may be heated by heatingthe mounting plate 20, such as with a thermoinduction welder or hotiron. In other instances, energy may be applied more directly to thecoating 90, such as with sonic welding. For example, the mounting plate20 may be affixed using the coating 90 such as by dielectrical or sonicor vibration welding, solvent bonding, heat bonding (such as usinginduction heating, infra red heating, hot air heating, or hot ironheating), any combination of the above, or in any other suitable manner.

It should be appreciated that thermoplastic coating 90, as well as thethermoplastic coatings described in the other embodiments herein, may berepresented in a variety of forms. Such forms include, but are notlimited to: solids, liquids, or any mixtures of material phases suitablefor the implementations disclosed herein.

A further example mounting system is shown in FIG. 3. FIG. 3 shows amounting plate 20 secured to a polymeric membrane 10 (e.g., athermoplastic membrane) with a binding agent 100. According to variousimplementations, the binding agent 100 may be, for example, a coating ofthermoplastic material applied to a contact surface of the mountingplate 20. With the thermoplastic coating, the mounting plate 20 may belocated at a desired location on the polymeric membrane 10 and heated tobind the mounting plate 20 to the polymeric membrane 10. Alternatively,any adhesive or carrier tape, such as the adhesives and carrier tapesdescribed above, may be used to secure the mounting plate 20 to themembrane 10. The combination of the mounting plate 20 and the polymericmembrane 10 may be considered a mounting assembly 110.

Referring still to FIG. 3, the mounting assembly 110 may be attached toa polymeric membrane 120. In the present example, the polymeric membrane120 may be a thermoplastic membrane. However, in other instances, thepolymeric membrane 120 may be a thermoset membrane. The mountingassembly 110 may be attached to the polymeric membrane 120 in numerousways. For example, the polymeric membrane 10 of the mounting assembly110 may be coupled to the polymeric membrane 120 using one or more ofthe methods described above in regards to the bonding of mounting plate20 to polymeric membrane 10. In other instances, a bonding agent 130,such as a carrier tape and/or adhesive (such as the carrier tape andadhesive, described respectively above) may be used. It should beappreciated that bonding agent 130 may be another bonding medium,including various bonding materials or various bonding members. Similarto above, the carrier tape may be applied in pieces, such as one or morestrips or sheets. Further, as also described above, the carrier tape maybe formed to correspond to geometry of the mounting assembly 110.

FIGS. 4 and 5 illustrate an alternate implementation for securing themounting assembly 110 to the polymeric membrane 120. As shown, a centralportion 140 of the mounting assembly 110 may be secured to the polymericmembrane 120 with an adhesive material 145, such as one or more piecesof carrier tape or adhesive, such as the carrier tape and adhesivedescribed above. Another attachment method or material may be usedaround a perimeter portion 150. For example, a coating of thermoplasticmaterial 155 at one or more locations along the perimeter portion 150may be used to secure the perimeter portion 150 to the polymericmembrane 120. The coating of thermoplastic material 155 may be bondedusing one or more of the methods described above. Alternately, one ormore of an adhesive or carrier tape may be used on the perimeter portion150. For example, the bonding material used on the perimeter portion 150may act to further secure the mounting assembly 110 or as awaterproofing material.

It is noted that, in some instances, a coating of thermoplastic materialmay be used to bond one thermoplastic membrane to another same orsimilar thermoplastic membrane. In other instances, the thermoplasticmaterial may be omitted. For example, some thermoplastic membranes maybe joined using one or more of the welding techniques above without theaid of a bonding material. On the other hand, a coating of thermoplasticmembrane may not be capable of bonding a thermoplastic membrane orthermoset membrane to another thermoset membrane. In such instances, anadhesive, such as an adhesive or carrier tape may be used to bond suchdissimilar materials to each other.

In some instances, the polymeric membrane 120 may be the same or asimilar thermoplastic as a thermoplastic forming the thermoplasticmembrane 10, such as one or more of the thermoplastics described above.However, the thermoplastics forming the respective thermoplasticmembrane 10 and the thermoplastic membrane 120 may be different whilestill bondable with or without the use of a thermoplastic material. Insome instances, the thermoplastic membrane 120 may form an outer surfaceof a roof structure. However, the description is not so limited, and thepresent description may be applicable to a thermoplastic membrane in anydesired application.

The mounting plate 20 may be of any desired shape. For example, themounting plate may be circular, rectangular, square, elongated, or be ofany other size or shape. Example mounting plates are illustrated inFIGS. 6-8. FIGS. 6A-6E show various views of a circular mounting plate20 having a plurality of concentric ridges 21 formed therein as well asa central cavity 22 that may be used to capture a head of a protrusion,as discussed in a similar manner above. As also described above, thecentral cavity 22 may accept a protrusion of different sizes. Theprotrusion may extend through opening 23.

Referring to FIGS. 7A-E, the example mounting plate 20 also includescavities 22 to accept the heads of protrusions. The protrusions mayextend through openings 23 formed in a wall of the cavities 22. FIGS.8A-D are various views of another example mounting plate 20. Themounting plate 20 may include various ridges 24 formed therein alongwith a cavity 22 and opening 23. Again, the cavity 22 may be used tocapture an end portion of a protrusion extending through the opening 23.The mounting plate 20 may also include openings 25 formed around aperiphery thereof.

Further, for the example mounting plate 20 shown in FIG. 6A-8D alongwith others within the scope of the disclosure, the cavities 22,openings 23, and/or the combination thereof may be operable to preventrotation of the protrusion relative to the mounting plate 20 while alsoaccepting protrusions of different sizes. Additionally, the respectivesizes of the ridges 24, openings 23, cavities 22, as well as otheraspects of the mounting plates 20 may be altered to any desired size.

Another example mounting system is shown in FIG. 9 in which a mountingplate 20 is disposed between a first polymeric membrane 500 and a secondpolymeric membrane 510. Fasteners 520 extend through the mounting plate20, the second polymeric membrane 510, and into a substructure 530. Thefirst polymeric membrane 510 overlays a first surface 540 of themounting plate 20 and includes an opening 550 through which theprotrusion 30 extends. A bonding material 560 may be used to adhere thefirst polymeric membrane 500 to the mounting plate 20.

In some instances, the bonding material 560 may be a coating of athermoplastic material applied to a portion of the first surface 540between the protrusion 30 and openings 570 formed in the mounting plate20 through with the fasteners 520 extend. Still further, in someinstances, the bonding material 560 may be applied and the firstpolymeric membrane 500 coupled therewith to the mounting plate 20 duringone or more manufacturing processes. That is, bonding the firstpolymeric membrane 500 to the mounting plate 20 with the bondingmaterial 560 may be performed remote from a job site, such as at amanufacturing facility. In other instances, the first polymeric membrane500 may be bonded to the mounting plate 20 with the bonding material 560at a jobsite. The bonding material 560 may be a coating of thermoplasticmaterial and used to bond the two components in one or more of themethods described above. In addition to adhering the first polymericmembrane 500 to the mounting plate 20, the bonding material 560 may alsoform a seal preventing or substantially preventing fluids frompenetrating through the opening 550 formed through the openings 570 andinto the substructure 530.

A bonding material 580 may also be applied to the first surface 540 ofthe mounting plate 20. In some instances, the bonding material 580 mayalso be used to secure the first polymeric membrane 500 to the mountingplate 20, such as after the fasteners 520 have been used to secure themounting plate 20 to the substructure 530. Utilizing the bondingmaterial 580 after fasteners 520 have been applied avoids the need topuncture the first polymeric membrane 500 for the fastener 570. Thus, insome instances, the bonding material 560 may be used to secure only aportion of the first polymeric membrane 500 to the mounting plate 20while still allowing passage of the fasteners 520 through the openings570 without the need to puncture the first polymeric membrane 500. Thebonding material 580 may be utilized thereafter to secure the firstpolymeric membrane 500 to the mounting plate 20 thereby also providing aseal. The first polymeric membrane 500 may also be secured to the secondpolymeric membrane 510 with a bonding material 590. Also, a coating orbonding material may be omitted where the polymeric membranes arecapable of being joined without such materials. For example, themembranes may be thermoplastic membranes capable of being joined usingone or more of the bonding techniques described above. In suchinstances, the bonding material 590 may be omitted.

A bonding material 600 may also be used to secure the mounting plate 20to the second polymeric membrane 510. The bonding materials 560, 580,590, and 600 cooperate to form a seal around the mounting plate 20 toaid in preventing or substantially reducing penetration of fluids and/ordebris into the substructure 530. One or more of the bonding materials560, 580, 590, and 600 may be a coating of a thermoplastic material andused to form a bond using one or more of the techniques described above.In some instances, the bonding materials 560, 580, and 590 may be thesame material, such as a coating of thermoplastic material 610, and maybe applied to the mounting plate 20, as shown in the example of FIG. 10.Alternately, one or more of the bonding materials 560, 580, 590, and 600may be a carrier tape or adhesive as also described above. In stillother implementations, one or more of the bonding materials 560, 580,590, and/or 600 may be omitted. For example, in some implementations,the polymeric membranes 500, 510 may be secured directly to each otherusing one or more of the joining techniques described above without theuse of a bonding material. Still further, the mounting plate 20 may alsobe formed from a material that is joinable to one or more of thepolymeric membrane 500 and/or polymeric membrane 510 without the use ofa bonding agent using one or more of the techniques described above. Insuch instances, one or more of the bonding materials 560, 580, and/or600 may be omitted.

The mounting plate 20 is shown with a protrusion 30 includes, althoughthe protrusion 30 may be omitted. Alternately, the mounting plate 20 maybe fixedly attached to another object. Still further, the mounting plate20 may have a mechanism for selectively attaching and detaching anotherobject.

FIGS. 11 and 12 show another example system 700 in which one or moremounting plates 710 are secured to a structure 720. For example, thestructure 720 may be a roof structure, although structure 720 is not solimited but may encompass other structures, such as one or more of thestructures identified above or other suitable structure. In someinstances, the mounting plates 710 may be coupled to the structure 720with fasteners, although the mounting plates 710 may be attached inother ways. A polymeric membrane 725 is applied over the mounting plates710, such as by unrolling a roll of the polymeric membrane 725. Anexample mounting plate 710 is shown in FIG. 12. The mounting plate 710may include a protrusion 730. Further, in some implementations, theprotrusion 730 may include a piercing portion 740 adapted to puncturethe polymeric membrane 725. Also, a portion of the protrusion 730 mayinclude a fastening portion 735 that may be used to attach a structureto the mounting plate. For example, in some instances, the fasteningportion 735 may be a threaded portion. However other fasteningmechanisms may also be used.

One or more of the mounting plates 710 may be secured to the structure720, such as in an array or any other configuration. The mounting plates710 may be secured with fasteners and/or with one or more of thetechniques described herein (e.g., using a coating of thermoplasticmaterial, carrier tape, adhesive, etc.). With the mounting plates 710secured to the structure 720, the polymeric membrane 725 may beoverlaid. The mounting plate 725 may be made to extend through thepolymeric membrane 725 such as by puncturing the polymeric membrane 725with the piercing portion 740. In other implementations, the polymericmembrane 725 may have preformed openings to allow the protrusions 730 toextend therethrough. The polymeric membrane 725 may be secured to themounting plate 710 using one or more of the techniques described above.For example, the mounting plate 710 may be coupled to the polymericmembrane 725 with a bonding material 727. The bonding material 727 maybe one or more of the materials discussed above and the coupling may beformed using one or more of the methods described above.

FIG. 13 shows another example system 900 including a mounting plate 910coupled to a substructure 920. Among other uses, the system 900 may beapplicable to roofing applications. The mounting plate 910 is shown asbeing attached with fasteners 930. However, other techniques may be usedto secure the mounting plate 910 to the substructure 920. The mountingplate 910 may include a protrusion 940 and a piercing portion 950.Further, in some implementations, the protrusion 940 may include afastening portion 955. Additionally, while the protrusion 940 is shownas an integral portion of the mounting plate 910, the protrusion 940 maybe attached to the mounting plate 910 using a fastening mechanism. Forexample, in some implementations, the protrusion 940 may be attached tothe mounting plate 910 via a threaded connection. An insulating member960 may be disposed above the substructure 920. An attachment member 970may be secured to the protrusion 940, such as by engaging the fasteningportion 950. In some implementations, the fastening portion 950 andattachment member 970 may have a threaded engagement, although otherattachment interfaces may be used. A polymeric membrane 965 overlays theinsulating member 960 and may be bonded to the attachment member 970with a bonding material 980. In some implementations, the bondingmaterial 980 may be a coating of thermoplastic material applied toattachment member 970. In other implementations, a carrier tape and/oran adhesive may be used to couple polymeric membrane 965 to theattachment member 970.

In addition, the described methods and systems can also reduce damage toa polymeric membrane. For example, when objects are unattached but arein contact, debris may become lodged between the object and thepolymeric membrane, and, because of the relative movement between thetwo, the debris may act as an abrasive on the polymeric membrane. Overtime, holes, rips, or other damage may occur to the polymeric membraneexposing the underlying structure to the environment, such as moisture,wind, etc. This exposure can cause damage to the structure. However, thepresent disclosure describes methods and systems that avoid thesedrawbacks.

Additionally, some of the methods and systems described herein alsoprovide for securing one or more objects to a polymeric membrane withoutpiercing the polymeric membrane. Consequently, objects remain attachedto the polymeric membrane without providing a pathway for moisture orother objects, e.g., insects, debris, etc., to pass through themembrane. Again, this can have particular value in waterproofingcovering applications where an unperforated covering is greatly desired.

Another example system 1000 is illustrated in FIG. 14. The system 1000includes a polymeric membrane 1010, a ridge member 1020, and a bondingmember 1030. In some implementations, the polymeric membrane 1010 mayform a portion of a roof structure, such as an exterior membrane. Theridge member 1020 may be coupled to the polymeric membrane 1010 by thebonding member 1030. In some instances, the bonding member 1030 may be adouble sided carrier tape similar to the carrier tape described above.In some implementations, the adhesive on the sides of the carrier tapemay be selected to provide a bond according to the material forming thepolymeric membrane 1010 and/or the ridge member 1020. In otherimplementations, the bonding member 1030 may be an adhesive selected toadhere polymeric membrane 1010 to the ridge member 1020. In someinstances, the adhesive may be an adhesive similar to the adhesivedescribed above.

The bonding member 1030 may occupy a channel 1040 formed in a base 1050of the ridge member 1020. Lips 1055 may also be formed in the ridgemember 1020 to aid in preventing intrusion of fluids and other materialsinto the channel 1040. A benefit of the bonding member 1030 is thatwhile coupling the ridge member 1020 to the polymeric membrane 1010, thebonding member 1030 may have a bonding strength less than the yieldstrength of the polymeric membrane 1010 and/or the ridge member 1020.Consequently, the bonding member 1030 will yield, separating the ridgemember 1020 from the polymeric membrane 1010 when a shearing load on theridge member 1020 exceeds the strength of the bonding member 1030.Consequently, the bonding member 1030 will yield without damaging eitherthe ridge member 1020 or the polymeric membrane 1010. For example, in anapplication in which the polymeric membrane 1010 and ridge member 1020form an exterior portion of a roof structure, a shearing force on theridge member 1020, for example, caused by a sheet of ice formed on theroof structure, would not tear the polymeric membrane 1010 as the icesheet moves down a slope of the roof. Rather, the shearing force wouldmerely sever the ridge member 1020 from the polymeric membrane 1010. Inother implementations, the bonding member 1030 may have a yield strengthequal to or greater than one or more of the ridge member 1020 and/or thepolymeric membrane 1010.

Referring now to FIGS. 15 and 16 in the drawings, FIG. 15 shows anoblique view of a mounting system 1501 according to the preferredembodiment of the present invention, while FIG. 16 shows an oblique viewof mounting system 1501 attached to a support structure 1601. It shouldbe appreciated that mounting system 1501 is substantially similar inform and function to the mounting systems described above. Like themounting systems disclosed herein, mounting system 1501 utilizes one ormore membranes to securely attach an object to the support structure,which includes, but should not be limited to a polymeric membrane and/ora rooftop. Mounting system 1501 comprises one or more membranes thatelastically extend as a force is exerted on the object attached thereto.Further description and illustration of the elastic membrane is providedwith reference to FIGS. 17-20C.

Mounting system 1501 comprises one or more of a first membrane 1503, asecond membrane 1505, and an object 1507. First membrane 1503 ispreferable composed of a polymeric material and is adapted to securelybond with at least a portion of second membrane 1505. It should beunderstood that first membrane 1503 is an optional membrane. Forexample, second membrane 1505 could attach directly to the supportstructure. However, as in most applications, the first membrane isadapted to attach directly to the support structure and the secondmembrane is adapted to bond to a top surface of the first membrane.

In the preferred embodiment, second membrane 1505 thermally fuses tofirst membrane 1503; however, it should be appreciated that alternativeembodiments could incorporate different methods for bonding secondmembrane 1505 to first membrane 1503, as disclosed herein and asconventional known in the art. Object 1507 is preferable a mountingplate substantially similar in form and function to the mounting platesdisclosed herein; however, it should be understood that object 1507should not be limited to a mounting plate, but could include otherdevices in lieu of a mounting plate. For example, in some embodiments,object 1507 could be an attachment device, i.e., a quick-release device,for securing a structure to mounting system 1501. Mounting system 1501is further provided with an optional protrusion 1509 adapted to attachto object 1507. Protrusion 1509 is substantially similar in form andfunction to the protrusions disclosed herein, wherein the protrusion isutilized for securing a riser (not shown) to mounting system 1501.

It should be understood that mounting system 1501 could include theadditional features of the mounting systems disclosed above. Forexample, mounting system 1501 could include a third polymeric material,a riser, a bonding medium, and/or other features described herein.Furthermore, the first and second membranes of mounting system 1501could be composed of the same elastic materials described herein inaddition to other suitable materials for providing elasticity to secondmembrane 1505 and/or any other desired membrane.

Referring now to FIGS. 17 and 18 in the drawings, front views ofmounting system 1501 are shown. FIG. 17 shows an assembled mountingsystem 1501, while FIG. 18 shows and exploded view of mounting system1501. Object 1507 includes a bottom surface 1801 which bonds to an uppersurface 1803 of second membrane 1505. Second membrane includes a lowersurface 1805 which bonds to a top surface 1807 of first membrane 1503.First membrane 1503 includes a bottom surface 1809 which attaches to atop surface 1811 of support structure 1601.

Referring to FIG. 19 in the drawings, a bottom view of second membrane1505 is shown. Lower surface 1805 preferably comprises two surfaceareas, a first surface area 1901 being adapted to extend peripherallyaround a perimeter of lower surface 1805, and a second remaining surfacearea 1903, which is preferably enclosed within surface area 1901. In thepreferred embodiment, area 1901 is bonded to top surface 1807 of firstmembrane 1503, while area 1903 remains separable from top surface 1807of first membrane 1503. This feature allows second membrane 1505 toelastically extend in a direction away from first membrane 1503 as aforce is exerted on object 1507.

Referring to FIGS. 20A-20C in the drawings, front views of mountingsystem 1501 are shown. FIGS. 20A-20C depicts second membrane 1505elastically extending away from support structure 1601. Specifically, asa force F is exerted on object 1507, second membrane 1505 elasticallyextends in the direction of the force, and then returns to its originalposition after the force dissipates. FIG. 20A shows mounting system 1501prior to force exerted against object 1507. FIG. 20B shows secondmembrane 1505 elastically extending in direction D1 as a force F isexerted on object 1507. FIG. 20C shows second membrane 1505 moving inthe direction D2, thus returning back to its original position afterforce F1 is applied.

Referring now to FIGS. 21 and 22 in the drawings, respective top andside cross-sectional views of a mounting plate 2101 are shown accordingto the preferred embodiment of the present invention. It should beappreciated that mounting plate 2101 is substantially similar infunction to the mounting plates shown and described herein.Specifically, mounting plate 2101 is adapted to secure an object such asa fastener, riser, attachment device, and/or other suitable device tothe mounting system.

During assembly, a worker attaches an object, i.e., a solar panelattachment, to the mounting plate, and in some embodiments, it is notfeasible to couple the object at a desired position and orientationbecause the raised surfaces of the mounting plate causes the object totilt. The mounting plate of the present invention overcomes suchproblems by extending the contact surface area between the mountedobject and the mounting plate, which in turn creates a relatively planarsurface area for mounting objects thereto. To do this, mounting plate2101 is provided with one or more elongated members adapted to extendfrom a primary housing. The housing and members form a relatively planarsurface area for supporting the object resting thereon. Of course, itshould be understood that mounting plate 2101 is not intended to belimited to the figures and description below, but could include thefeatures of the mounting plates described herein and other modificationswithout departing from the spirit thereof.

Mounting plate 2101 comprises a housing 2103 raised from a base 2105,the housing being adapted to receive and support an object, i.e., ariser (not shown) thereon. Housing 2103 preferably forms a cavity 2201for receiving a bolt, nut, and/or other any other type of fastener.However, it should be appreciated that alternative embodiments couldinclude a solid housing, in lieu of a hollow cavity, and a shaftdisposed therein for fastening to the object. Housing 2103 creates acontact surface area 2107, which receives and supports the objectattached to mounting plate 2101.

Mounting plate 2101 is provided with one or more elongated members 2109with a top surface area 2111 having a height relative flush with contactsurface area 2107. Members 2109 are adapted to extend the contactsurface area between the object and mounting plate 2101, which in turncreates a relatively planar surface area for mounting objects thereto.In the preferred embodiment, housing 2103 and members 2109 form acontinuous contact surface area. However, it should be appreciated thatalternative embodiments could include members spaced apart from housing2103. For example, alternative embodiments could include one or moreisolated members spaced apart from the housing and adapted to receiveand maintain a flush surface area with the housing for mounting anobject thereon.

In the preferred embodiment, mounting plate 2101 comprises fiveelongated members 2109, each member having a longitudinal centerline A,and each longitudinal centerline A being oriented at the same angle Brelative to each other on a surface planar to base 2105. It should beappreciated that alternative embodiments could include more lesselongated members for supporting the object. For example, alternativeembodiments could include three members in lieu and/or different anglesrelative to each other.

Mounting plate 2101 is further provided with one or more optional holes2113 for receiving a fastener (not shown) and a hole 2115 extendingthrough the thickness of housing 2103. Hole 2115 is utilized to eitherreceive a attachment device, i.e., a fastener, of the object beingattached thereon or adapted to allow a fastener to extend therethroughfor fastening to the object. In some embodiments, hole 2115 could bethreaded for threadingly engaging with a threaded fastener. Mountingplate 2101 also includes an optional rim 2117 extending peripherallyalong an edge of base 2105. It should be appreciated that although shownin the circular form, mounting plate 2101 could easily be manufacturedin different geometric shapes, depending on the desired application.

Referring to FIG. 23 in the drawings, a cross-sectional side view ofmounting plate 2101 taken at XXII-XXII is shown attached to mountingsystem 1501. In the preferred embodiment, an adhesive, as describedherein, is applied to a bottom surface 2203 of mounting plate 2101 andthereafter bonded, preferably thermally fused, to membrane 1505 ofmounting system 1501. In the exemplary embodiment, a fastener 2301 isshown securely positioned within cavity 2201.

Referring now to FIG. 24 in the drawings, a front view of an alternativeembodiment of mounting plate 2101 is shown. Mounting plate 2401 isadapted with a perforated surface area 2403. The perforated areas allowthe membrane of the mounting system to extend therethrough as heat isapplied to the membrane. Thereafter, the membrane securely bonds toabove, within, and below the perforated areas after the membrane iscooled.

It should be appreciated that mounting plate 2401 is substantiallysimilar in function to the mounting plates shown and described herein.Specifically, mounting plate 2401 is adapted to secure an object such asa fastener, riser, attachment device, and/or other suitable device tothe mounting system. The features of the mounting plates describedherein could easily be adapted to include the features of mounting plate2401, and likewise mounting plate 2401 could be adapted to include thefeatures of the mounting plates described herein. Of course, it shouldbe understood that mounting plate 2401 is not intended to be limited tothe embodiment shown in FIG. 24, but includes the features of themounting plates described herein and other modifications withoutdeparting from the spirit thereof.

Referring now to FIGS. 25 and 26 in the drawings, FIG. 25 shows anoblique view of a riser 2501 according to the preferred embodiment ofthe present invention, while FIG. 26 shows a front cross-sectional viewof riser 2501 taken at XXVI-XXVI of FIG. 25. In the preferredembodiment, riser 2501 is adapted to couple to and elevate an object,i.e., an attachment device for a solar panel, at a desired height,preferably 4 inches, above a structure. It should be understood that,riser 2501, and the alternative embodiments disclosed herein, areadapted to couple to one or more of the mounting systems describedherein and/or other modifications without departing from the spiritthereof. In addition, it should be appreciated that riser 2501 and otheralternative embodiments thereof could easily be adapted to fasten toother types of devices in lieu of a mounting assembly.

Riser 2501 is preferably composed of a rigid, metallic material such asaluminum, which allows lithe to no flexure, thus restricting transverse,longitudinal, and rotational movement of riser 2501. The metallicmaterial allows an object, such as a solar panel, to rigidly attach tothe structure via riser 2501. However, it should be appreciated thatalternative embodiments of riser 2501 could be composed of differentmaterials, both flexible and rigid, depending on the preferredapplication. For example, riser 2501 could be composed, partially or inwhole, of a composite, wood, and/or an elastomeric material, whichcreates flexibility, conductive resistance, and/or other desiredattributes.

Riser 2501 provides significant advantageous over conventional devicesfor securing an object to a roof structure. Specifically, riser 2501 ispreferably manufactured through an extruding process, wherein multiplerisers are formed simultaneously as a continuously extruded member.During the manufacturing process, the extruded member is transverselycut to form individual risers. Then, two opposing holes are machined onopposing surfaces of the riser for attaching the riser to both themounting plate and the object coupled thereto. The relatively simpledesign and advanced extruding process greatly reduces the manufacturingcosts.

Riser 2501 comprises an attachment portion 2503 for securing an objectto riser 2501 and a base portion 2505 for coupling riser 2501 to one ormore mounting systems described herein. In the exemplary embodiment,riser 2501 is adapted to attach to mounting assembly 110, which in turnattaches to a roof structure. Of course, it should be understood thatalthough described as being utilized with a roof structure, riser 2501could easily be utilized with other structures in lieu of the preferredroof structure, i.e, a vertical wall, membrane for covering ponds,and/or other suitable structures.

Riser 2501 comprises a first sidewall 2507 and a second sidewall 2509extending relatively parallel to each other. The sidewalls are adaptedto elevate attachment portion 2503 at a predetermined height relative tothe structure (not shown). Riser 2501 further comprises a firstattachment device 2511, which is preferable a hole extending through thethickness of base 2505 and a second attachment device 2513, which ispreferable a hole extending through the thickness of attachment portion2503. Attachment device 2511 is adapted to couple riser 2501 to themounting plate, while attachment device 2513 is adapted to couple anobject to riser 2501.

Base 2505 preferably includes two elongated leg members, a first leg2515 and a second leg 2517, both legs being adapted to elevate base 2505at a height H1 above the top surface of the mounting plate. In thepreferred embodiment, leg 2515 and leg 2517 elevate base 2505 above oneor more raised surfaces of the mounting plate. For example, the mountingplate, as shown and described above, could include a raised surfacedirectly underneath base 2505, thereby requiring base 2505 to be raisedat a height H1 to create a tight, secure fit between riser 2501 and themounting system. It should be appreciated that leg 2515 and leg 2517 areoptional features and are not required in alternative embodimentswherein the mounting plate is devoid of raised surfaces below base 2505.In these alternative embodiments, base 2505 could easily be adapted tosit directly on the top surface of the mounting plate.

Attachment portion 2503 includes one or more surfaces for abuttingagainst the object coupled thereto (see FIG. 27). Attachment portion2503 preferably comprises six surfaces, a front surface 2519, anopposing rear surface 2521, a side surface 2523, an opposing sidesurface 2525, a first top surface 2527, a second top surface 2529, andan elevated top surface 2531. In the preferred embodiment, riser 2501has a length L, a top surface width W1 extending the width of surface2529, a top surface width W2 extending the width of surface 2531, a topsurface width W3 extending the width of surface 2527, and a height H2extending the height between top surface 2531 and surface 2529. In thepreferred embodiment, W2 is greater than W1 or W3 and H2 has a length ofapproximate ⅜ of an inch. Of course, it should be understood that theforegoing lengths, widths, and heights are not intended to limit riser2501 to these dimensions. It should be appreciated that alternativeembodiments could include different dimensions depending on the desiredapplication.

In the preferred embodiment, an object 2701, like that shown in FIG. 27,rests on top surface 2531 and/or top surfaces 2527 and 2529. Sidesurfaces 2527 and 2529 and/or front surface 2519 and rear surface 2521provide means for restricting movement of the object. For example, theobject could include a surface extending alongside surface 2523, whichcreates contact and restricts rotational movement of the object asrotational torque is applied thereto.

Referring now to FIG. 27 in the drawings, a front cross-sectional viewof riser 2501 is shown attached to mounting assembly 110 and shownattached to an object 2701. It should be noted that the term mountingassembly and mounting system are interchangeable used herein, andintended to refer to a system adapted to secure an object to astructure. It should also be noted that the front view of mountingassembly 110 is depicted in FIG. 4 above. When assembled, protrusion 30extends through attachment device 2511, which in turn, is received by anattachment device 2703 for securing base 2505 to assembly 110. In thepreferred embodiment, attachment device 2703 is a nut 2705 threadinglyengaged with protrusion 30; however, it should be appreciated thatalternative embodiments could include different attachment devices,i.e., a quick release device, snap, clip, and/or other suitable devicesin lieu of the preferred embodiment.

Attachment device 2511 is preferable a non-threaded hole, which allowsthe protrusion to slide therein, while attachment device 2513 ispreferably a threaded hole, which provides attachment means for athreaded bolt and/or other suitable device. It should be appreciatedthat alternative embodiments could include either threaded ornon-threaded holes in lieu of the preferred embodiment.

During assembly, riser 2501 is positioned on plate 20 such that hole2511 receives protrusion 30. Thereafter, riser 2501 is attached to plate20 with attachment device 2703 such that the legs of riser 2501 securelycontact the top surface of plate 20. Finally, object 2701 is placed onattachment portion 2503 and secured with attachment device 2707, i.e, abolt 2709.

Referring now to FIGS. 28 and 29 in the drawings, FIG. 28 shows anoblique view of a riser 2801 according to an alternative embodiment ofthe present invention, while FIG. 29 shows a front cross-sectional viewof riser 2801 taken at XXIX-XXIX of FIG. 28. It should be noted thatriser 2801 is substantially similar in function to riser 2501, whereinboth riser 2801 and riser 2501 are adapted to elevate an object at apredetermined height above a structure and both risers are adapted tosecurely attach to a mounting assembly. The features of riser 2801 couldeasily be incorporated in riser 2501, and likewise, the features ofriser 2501 could be incorporated in riser 2801.

Riser 2801 comprises an attachment portion 2803 for securing an objectto riser 2801 and a base portion 2805 for attaching riser 2801 to amounting assembly. Base portion 2805 is preferably a separate memberrigidly attached to attachment portion 2803 through bonding means, i.e.,welding, to form a unitary body with attachment portion 2803. However,it should be appreciated that attachment portion 2803 and base 2805could easily be manufactured as a single member in alternativeembodiments. For example, riser 2801 could be manufactured through alathing or milling process.

Riser 2801 comprises a first attachment device 2807, which is preferablya hole, and a second attachment device, which is preferable a hole, bothholes being adapted to extend partially through the thickness ofattachment portion and base portion, respectively. Attachment device2811 is adapted to couple riser 2801 to mounting assembly 110, whileattachment device 2807 is adapted to secure an object to riser 2801. Itshould be appreciated that alternative embodiments could include acontinuous conduit interconnecting the two opposing attachment devicesin lieu of the preferred embodiment. In the preferred embodiment,attachment device 2811 threadingly engages with protrusion 30 ofmounting assembly 110, and attachment device 2807 threadingly engageswith a threaded bolt and/or other suitable attachment device.

In the exemplary embodiment, riser 2801 attaches to mounting assembly110. Of course, it should be understood that riser 2801 could easily beattached to other types of mounting assemblies, either attached to aroof structure or other types of structures.

During assembly, riser 2801 is positioned on plate 20 such thatattachment device 2811 receives protrusion 30. Thereafter, a workerrotates riser 2801, which in turn, causes attachment device 2811 tothreadingly engage with protrusion 30. Finally, an object is placed onsurface 2809 and secured with an attachment device (not shown), i.e., afastener adapted to engage with attachment device 2807.

Riser 2801 is further provided with a cavity 2815 for receiving a raisedsurface of the mounting plate. It should be appreciated that cavity 2815is an optional feature and is not required in alternative embodimentswhere the mounting plate is devoid of raised surfaces directly beneathsurface 2813. In these alternative embodiments, base 2805 could easilybe adapted to sit directly on the top surface of the mounting plate.

Referring now to FIGS. 30 and 31 in the drawings, FIG. 30 shows anoblique view of a riser 3001 according to an alternative embodiment ofthe present application, while FIG. 31 shows a front cross-sectionalview of riser 3001 taken at XXXI-XXXI of FIG. 30. FIG. 31 also showsriser 3001 coupled to mounting assembly 110, as depicted in FIG. 4above. It should be appreciated that riser 3001 is substantially similarin function to riser 2801 and riser 2501, wherein riser 2801, riser 2501and riser 3001 are adapted to raise an object at a predetermined heightabove a structure and adapted to securely attach to a mounting assembly.The features of riser 3001 could easily be incorporated in both risers2501 and 2801, and likewise, the features of risers 2501 and 2801 couldbe incorporated in riser 3001.

Like risers 2501 and 2801, riser 3001 comprises an attachment portion3003 for securing an object to riser 3001 and a base 3005 for attachingriser 3001 to a mounting assembly. In the preferred embodiment, riser3001 is formed as a single member, preferably manufactured through theextruding process described above. Riser 3001 is provided with a firstattachment device 3007, which is preferable a hole extending through thethickness of attachment portion 3003 and a second attachment device3009, which is preferably a hole extending through the thickness of base3005. Attachment device 3007 provides means for attaching riser 3001 tothe roof structure, while attachment device 3009 provides means forsecuring an object to riser 3001.

Riser 3001 is further provided with a structure 3011, which can eitherbe separable from or rigidly attached to base 3005 through a bondingprocess, i.e., welding, to form a unitary body with base portion 3005.Structure 3011 elevates base 3005 above a raised surface area (notshown) of the mounting plate. Structure 3011 is provided with a cavity3013 extending through the thickness of structure 3011 for receiving theraised surface and for allowing protrusion 30 to extend therethrough.

During assembly, riser 3001 is positioned on plate 20 such that hole3013 and hole 3007 receive protrusion 30. Thereafter, an attachmentdevice 3015, i.e., a bolt 2117, attaches to protrusion 30 for securingriser 3001 to mounting assembly 110. Finally, an object is coupled toeither a surface 2019 and/or a surface 2021 of attachment portion 3003and secured with an attachment device (not shown) adapted to couple tohole 3009.

Referring now to FIG. 32 in the drawings, an oblique view of analternative embodiment of riser 2501 is shown. Riser 3201 issubstantially similar in function to the risers described herein.Specifically, riser 3201 is adapted to elevate an object at apredetermined height above a structure via one or more of the mountingsystems described herein. The features of riser 3201 could easily beincorporated in the risers described herein, and likewise the featuresof risers disclosed herein could be incorporated in riser 3201.

Riser 3201 comprises one or more of an attachment portion 3203 having atop surface 3205 and an opposing base portion 3207 having a bottomsurface 3209. Attachment portion 3203 is adapted to support and attachto an object thereon, while base portion 3207 is adapted to secure riser3201 to one or more of the mounting systems described herein.

Riser 3201 further comprises a sidewall 3211 rigidly attached toattachment portion 3203 and base portion 3209. Sidewall 3211 elevatesattachment portion 3203 at a predetermined height, preferably around 4inches above a structure the mounting system is attached thereto. In thepreferred embodiment, sidewall 3211 is manufactured in a curved profile,which is formed through a stamping manufacturing process. It should beappreciated that other profiles, i.e., rectangular profiles, could beutilized in lieu of the preferred embodiment. The curved profileprovides sufficient rigidity for supporting the object coupled toattachment portion 3203. In the preferred embodiment, riser 3201 ismanufactured with a stamping process; however, it should be appreciatedthat alternative manufacturing process, i.e., milling, could be utilizedin lieu of the preferred process.

Sidewall 3211 curves from a first end 3213 to a second end 3215. In thepreferred embodiment, sidewall 3211 does not attach to the entire edgedsurfaces of attachment portion 3203 and base portion 3207. Attachmentportion 3203 includes a top tab portion 3217, while base portion 3207includes a bottom tab portion 3219. However, it should be appreciatedthat alternative embodiments could include a sidewall that attach to theentire edged surfaces of the top and bottom members.

Riser 3201 further comprises a first attachment device 3221, which ispreferable a hole extending through the thickness of attachment portion3203 and a second attachment device 3233 extending through the thicknessof base portion 3207. In the preferred embodiment, attachment portion3221 is adapted to couple to the object being mounted thereto, andattachment portion 3223 is adapted to couple riser 3201 to one or moreof the mounting systems described herein. It should be appreciated thatattachment device 3221 and/or attachment device 3223 could either bethreaded or unthreaded, depending on the preferred application.

Referring now to FIGS. 33 and 34 in the drawings, oblique andcross-sectional views of a mounting plate 3301 according to a preferredembodiment of the present application are shown. Mounting plate 3301 issubstantially similar in function to the foregoing mounting plates. Inparticular, mounting plate 3301 is utilized to secure an object, i.e., ariser, to one or more of mounting systems discussed herein. It will beappreciated that the features of mounting plate 3301 and the foregoingmounting plates are interchangeable, for example, mounting plate 3301could include the features of the mounting plate 2101 and/or mountingplate 2401. Like the foregoing mounting plates, mounting plate 3301preferably thermally bonds to upper surface 1803 of second membrane1505. In the preferred embodiment, mounting plate 3301 is utilized withmounting system 1501; however, it will be appreciated that mountingplate 3301 could easily be utilized with alternative embodiments ofmounting system 1501.

Mounting plate 3301 comprises a raised portion 3303 being raised at aheight relative to a base 3305. Base 3305 includes a bottom surface area3403, which thermally bonded to second membrane 1501 according to one ormore of the bonding methods discussed herein. In the preferredembodiment, mounting plate 3301 is composed of a metallic materialsufficiently rigid to support an object to the mounting system in arelatively fixed position, yet sufficiently elastic to receive differentembodiments of a fastener, as will be discussed in detail below (seeFIGS. 37 and 38).

Mounting plate 3301 is preferably formed through a stamping process,which provides easy and rapid manufacturing of raised portion 3303. Thestamping process is an effective means for forming raised portion 3303;however, it should be appreciated that alternative embodiments ofmounting plate 3301 could be composed of other materials, including butnot limited to, plastics, ceramics, composites, elastomeric material,and/or other suitable materials and could be manufactured throughalternative machining processes such as milling, extrusion, molding,and/or other suitable manufacturing processes.

Raised portion 3303 is utilized to secure a fastener 3403 to mountingsystem 1501. In the preferred embodiment, raised portion 3303 is adaptedto sandwich fastener 3403 between a lower surface area 3405 and uppersurface area 1803 of second membrane 1505. Raised portion 3303 forms acavity 3407 for receiving fastener 3403. Cavity 3407 is formed with alower surface 3405 and a contoured joining material 3307. Joiningmaterial 3307 extends from base 3305 to a top surface 3309 and includesan inner surface 3409 selectively contoured to abut against the top andside surfaces of fastener 3403. Thus, the snug fit between the surfacesof fastener 3403 and inner surfaces of cavity 3405 prevent rotational,transverse, and longitudinal movement of fastener 3403, which in turnenables an object attached thereto to remain in a relatively fixedposition while mounted to mounting system 1501.

It should be appreciated that alternative embodiments of raised portion3303 could include cavities which are not formed with contoured innersurfaces adapted to create a snug fit with the fastener. In thesealternative embodiments, the fastener disposed therein is capable ofsome movement, depending on the preferred application. For example, theraised portion could be configured to enable rotational movement, whilerestricting transverse and longitudinal movement. An example of thistype of embodiment is found in FIG. 38, as will be discussed below.

Raised portion 3303 is further provided with a port 3311 extendingthrough the thickness formed between top surface area 3309 and lowersurface area 3405. Port 3311 provides passage for a fastening device,i.e., a threaded shaft (not shown), to extend therethrough and fasten toan attachment device 3411 of fastener 3403. In the preferred embodiment,port 3311 is a hole, either partially or fully extending throughthickness T of fastener 3403, and is preferably threaded for engaging athreaded member of an object being supported thereto. However, it willbe appreciated that alternative embodiments of fastener 3403 couldinclude different fastening means, i.e., slots, clips, clamps,quick-release devices, in lieu of the preferred embodiment. Also,alternative embodiments could include a protrusion extending throughport 3311 and adapted to couple to the object (see FIG. 36).

Mounting plate 3301 is optionally manufactured with a rim 3313 extendingaround the peripheral edge of base 3307 and oriented at an angle withrespect to and in a direction away from base 3307. Rim 3313 providesmeans for preventing water, debris, and/or other foreign objects fromentering and/or blocking port 3311. Also, rim 3313 could provideattachment means for coupling an attachment device, i.e., a clip orclamp, to mounting plate 3301.

FIG. 35 shows an oblique view of fastener 3403. Fastener 3403 comprisesa base 3501 and one or more anti-rotational members 3503 extendingtherefrom. Members 3503 are utilized to prevent transverse,longitudinal, and rotational movement of fastener 3403 while fastener3403 is disposed within cavity 3407. Specifically, members 3503 and base3501 include a side surface 3505 that abuts against inner surface 3409of joining material 3307, thereby creating a snug fit therebetween andpreventing movement. In the preferred embodiment, fastener 3403comprises four members 3503; however, alternative embodiments couldinclude more or less members depending on the preferred application.Fastener 3403 is further provided with a top surface 3507, which comesin contact with surface 3405, and a bottom surface 3509, which comes incontact with upper surface 1803 of second membrane 1501. Duringoperation, movement of fastener 3403 is restricted when the side, top,and bottom surfaces of the fastener abut against the inner surfaces ofcavity 3407 and surface 1803 of membrane 1501 as forces are exertedagainst fastener 3403.

FIG. 36 shows an oblique view of an alternative embodiment of fastener3403. Fastener 3601 is substantially similar in form and function tofastener 3403. For example, fastener 3601 is provided with one or moreanti-rotational members 3603 extending from a base 3605 and adapted toprevent rotational, longitudinal, and transverse movement of fastener3601 when sandwiched between surface 3405 and surface 1803.

Fastener 3601 is further provided with a protrusion 3607 extending frombase 3605. Fastener 3601 is preferably manufactured as an integralmember with protrusion 3607, thus being rigidly formed with base 3605.Protrusion 3607 is utilized to provide coupling means for attaching anobject to fastener 3601. Protrusion 3607 is further optionally providedwith an attachment portion 3609 utilized to couple with the object. Inthe preferred embodiment, attachment portion 3609 preferably includesthreads for engaging with a threaded member of the object. Of course itshould be appreciated that alternative embodiments of attachment portion3609 could include different surface treatments and/or device in lieu ofthe preferred embodiment.

Referring now to FIGS. 37 and 38 in the drawings, a cross-sectional viewof an alternative embodiment of fastener 3601 is shown. Fastener 3701 issubstantially similar in form and function to fastener 3601. Forexample, fastener 3701 comprises a base portion 3703 and a protrusion3705 extending therefrom. It will be appreciated that the features offastener 3701 and the foregoing fasteners are interchangeable, forexample, fastener 3701 could include the features of fastener 3601.

Fastener 3701 is further provided with a notch 3707 utilized to couplefastener 3701 to port 3311. In the preferred embodiment, notch 3707 isadapted to tightly fit with port 3311, which in turn preventsrotational, longitudinal, and transverse movement of fastener 3701,thereby eliminating the need to sandwich fastener 3701 within cavity3407 of raised portion 3303. It should be appreciated that alternativeembodiments of notch 3707 could be utilized to allow some movement,i.e., rotational movement, depending on the preferred application. Notch3707 peripherally extends around protrusion 3705 and comprises a bottomsurface 3709, a top surface 3711, and an inner side surface 3713. Acontoured surface 3715 is positioned above notch 3707 and is utilized toelastically deform the material around port 3311 such that the materialwidens while in contact with surface 3715, then retracts to its originalgeometric shape in notch 3707.

Referring now to FIG. 39 in the drawings, an alternative embodiment ofmounting plate 3301 is shown. Mounting plate 3901 is substantiallysimilar in function to mounting plate 3301. In particular, mountingplate 3901 is adapted to secure an object, i.e., a riser to mountingsystem 1501. It will be appreciated that mounting plate 3901 couldinclude the features of the other mounting plates discussed herein, andlikewise, the features of mounting plate 3901 could be incorporated inthe foregoing mounting plates.

Mounting plate 3901 is provided with a protrusion 3903 extending from abase portion 3903. Protrusion 3903 is utilized to couple an object tomounting plate 3901. FIG. 40 shows a cross-sectional view of mountingplate 3901 taken at XL-XL of FIG. 39. As is shown, protrusion 3903 andbase 3905 are preferably formed as an integral body, and preferablymanufactured through a stamping process. Protrusion is provided with anattachment portion 3907, which in the preferred embodiment, is a ridgerecessed on the surface of protrusion 3903. Although shown as anelongated rectangular member, protrusion 3903 can easily be manufacturedwith different shapes and sizes. For example, an alternative embodimentcould include a cylindrical protrusion in lieu of a rectangular profile.Also, alternative embodiments could include different attachment devicesin lieu of a ridge. For example, attachment portion 3907 could includethreads for engaging a threaded structure.

FIG. 41 shows a flow chart 4101 illustrating the preferred method of themanufacturing the mounting systems disclosed herein. Box 4103 shows thefirst step, which includes providing an elastic membrane having an upperand lower surface. The next step includes placing and bonding a mountingplate to the upper surface with heat and pressure, as depicted in boxes4105 and 4107. Thereafter, the mounting plate is secured in place with amagnet positioned on the opposing lower surface, as depicted in box4109. Finally, the magnet is removed after sufficient time is allowed tocool the mounting plate, as depicted in boxes 4111 and 4113.

FIG. 42 shows a flow chart 4201 illustrating the preferred method of themanufacturing and assembling the mounting systems with plate 3301. Box4203 includes the first step, which includes providing a membrane,mounting plate, and a fastener. The next step includes securing thefastener to the mounting plate, which includes the steps of firstforming a cavity having the contouring of the fastener, as depicted inboxes 4205 and 4207. The next step includes placing and bonding amounting plate to the upper surface with heat and pressure, as depictedin boxes 4209 and 4211. Thereafter, the mounting plate is secured inplace with a magnet positioned on the opposing lower surface, asdepicted in box 4213. Finally, the magnet is removed after sufficienttime is allowed to cool the mounting plate, as depicted in boxes 4215and 4217.

Referring to FIGS. 43 and 44 in the drawings, unassembled and assembledfront views of an alternative embodiment of mounting system 1501 isshown. Mounting system 4301 is substantially similar in form andfunction to mounting system 1501. The features of the mounting systemsdescribed herein could easily be adapted to include the features ofmounting system 4301, and likewise mounting system 4301 could be adaptedto include the features of the foregoing mounting system describedherein.

Mounting system 4301 is further provided with one or more fasteningdevice 4303 utilized to secure membrane 1503 to structure 1601. FIG. 44shows fastening devices 4303 securing membrane 1503 to structure 1601 asforce F is exerted against mounting system 4301, which in turn causeselastic stretching of membrane 1505.

Referring now to FIGS. 45 and 46 in the drawings, an alternativeembodiment of mounting system 1501 is shown. FIG. 45 shows an explodedoblique view of mounting system 4501, while FIG. 46 shows an assembledoblique view of mounting system 4501. Mounting system 4501 issubstantially similar in form and function to the mounting systemsdescribed above, namely, mounting system 4501 comprises one or moremembranes adapted to secure an object to a structure, i.e., a polymericmembrane, rooftop, and/or other rigid or non-rigid type of structure. Itshould be appreciated that the features of mounting system 4501 could beincorporated in any of the foregoing mounting plates, and likewise,mounting system 4501 could be adapted to include the mounting platefeatures disclosed herein.

Mounting system 4501 comprises a second membrane 4503, substantiallysimilar in function to membrane 1505, and a first membrane 4505. Firstmembrane is preferably a flashing membrane, which securely bonds to astructure 4507, i.e., a rooftop at end 4509 and at end 4511 according toone or more of the bonding methods discussed above. It should be notedthat the entire bottom surface of first membrane 4505 is not bonded tostructure 4507 in the preferred embodiment. For this reason, mountingsystem 4501 is further provided with a bracket 4513 adapted to securelyfasten a portion of first membrane 4505 to structure 4507. One or morefastener means 4515 are utilized to secure bracket 4513, which in turnsecures a portion of first membrane 4509, to structure 4507. Bracket4513 forms a hollow area 4517, which enables a portion of first membraneto extend therethrough when a force is exerted against mounting plate4591 bonded to second membrane 4503.

In the preferred embodiment, a single bracket 4513 is utilized to securefirst membrane 4505 to structure 4507; however, it will be appreciatedthat alternative embodiments could include two or more brackets in lieuof the preferred embodiment. For example, an alternative embodimentcould include a second bracket having a smaller diameter than bracket4513 and adapted to fit within hollow area 4517. The two bracketsprovide additional means for securing the first membrane to thestructure. In the preferred embodiment, bracket 4513 is composed of ametallic material; however, alternative embodiments could includedifferent materials, i.e., wood, composite, plastic, and/or othersuitable materials, both rigid and flexible, in lieu of the preferredembodiment. Bracket 4513 is also preferably circular in shape; however,it will be appreciated that alternative embodiments could includedifferent geometric shapes, sizes, and embodiments wherein the bracketdoes not form a unitary body.

Referring now to FIGS. 47 and 48 in the drawings, respectivecross-sectional and front views of mounting system 4501 are shown as aforce F is exerted against mounting plate 4517. Mounting system 4501 isfurther provided with a bonding material 4701 utilized to bond a portionof second membrane 4503 to first membrane 4505 within hollow area 4517.

FIG. 48 shows the effects of force F exerted against mounting system4501 when bracket 4513 is not utilized. As is shown, a large gap 4801 isformed between first membrane 4505 and structure 4507. In this exemplarydepiction, first membrane 4505 remains securely bonded to structure 4507at ends 4509 and 4511, while the remaining area is separated.

The particular embodiments disclosed above are illustrative only, as theinvention may be modified and practiced in different but equivalentmanners apparent to those skilled in the art having the benefit of theteachings herein. It is therefore evident that the particularembodiments disclosed above may be altered or modified, and all suchvariations are considered within the scope and spirit of the invention.Accordingly, the protection sought herein is as set forth in thedescription. It is apparent that an invention with significantadvantages has been described and illustrated. Although the presentinvention is shown in a limited number of forms, it is not limited tojust these forms, but is amenable to various changes and modificationswithout departing from the spirit thereof.

What is claimed is:
 1. A method to restrict movement of a fastener for amounting system, the method comprising: providing a mounting platehaving a base portion and a raised portion, the raised portion forming acavity with an inner surface; contouring the inner surface of the cavityto match the contouring of the fastener; placing the fastener within thecavity; placing the mounting plate on a membrane of the mounting systemsuch that the fastener is disposed between the mounting plate and themembrane; thermally bonding the base portion of the mounting plate tothe membrane; and partially bonding the membrane to the supportstructure such that the membrane elastically extends in a direction awayfrom the roof as a force is exerted against the mounting plate.
 2. Themethod of claim 1, further comprising: providing access to the fastenervia a port extending through a thickness of the raised portion; andsecuring the fastener to the port with a notch recessed in a protrusionattached to the fastener.
 3. The method of claim 1, further comprising:restricting rotational movement of the fastener by providing ananti-rotational member attached to and extending from a base of thefastener.
 4. The method of claim 1, wherein the fastener is tightlysandwiched between the mounting plate and the membrane, thus restrictingmovement of the fastener.
 5. A mounting system for attaching an objectto a support structure, the system comprising: a fastener having: abase; an attachment device carried by the base, the attachment devicebeing adapted to couple with the object; and a first anti-rotationalmember extending from the base, the first anti-rotational member having:a side surface; and a top surface; a mounting plate having: a baseportion having: a bottom surface; and a raised portion, the raisedportion being raised at a height relative to the base portion, theraised portion forming a cavity adapted to receive the firstanti-rotational member, the cavity having: an inner surface areacontoured to abut against the side surface and the top surface of thefirst anti-rotational member; and an elastic membrane having: an uppersurface, the upper surface being bonded to the bottom surface of thebase portion of the mounting plate; a lower surface, the lower surfacebeing thermally bonded to the support structure; wherein the elasticmembrane is partially separable from the support structure andconfigured to elastically extend in a direction away from the roof as aforce is exerted against the mounting plate; wherein the fastener issandwiched between the mounting plate and the membrane; and wherein thecavity of the raised portion restricts movement of the fastener as aforce is exerted on the object.
 6. The mounting system of claim 5,wherein the lower surface area of the elastic membrane comprises: afirst surface area, the first surface area extending peripherally alongat least a portion of a perimeter of the lower surface; and a secondsurface area, the second surface area being at least partially enclosedwithin the first surface area, the second surface area being positionedat least partially below the mounting plate, the second surface areabeing separable from the support structure such that the second surfacearea elastically extends in a direction away from the support structureas a force is exerted on the object.
 7. The mounting system of claim 5,wherein the attachment device is a hole extending through a thickness ofthe fastener.
 8. The mounting system of claim 7, wherein the hole istreaded.
 9. The mounting system of claim 5, wherein the attachmentdevice is a protrusion extending in a direction away from the base, theprotrusion having: an attachment portion adapted to couple to theobject.
 10. The mounting system of claim 5, further comprising: a secondanti-rotational member; a third anti-rotational member; and a fourthanti-rotational member; wherein the second, the third, and the forthanti-rotational members extend from the base of the fastener; andwherein the cavity of the raised portion is adapted to receive thefirst, the second, the third, and the fourth anti-rotational members;and wherein the second, the third, and the forth anti-rotational membersare adapted to prevent movement of the fastener while disposed in thecavity.
 11. The mounting system of claim 5, the raised portioncomprising: a port extending through a thickness of the raised portion,the port being adapted to provide access to the attachment device of thefastener.
 12. The mounting system of claim 5, further comprising: a portextending through a thickness of the raised portion; and a protrusionattached to and extending in a direction away from the base of thefastener, the protrusion having: a notch; wherein the protrusion extendsthrough the port; and wherein the port is adapted to fit within thenotch.
 13. The mounting system of claim 5, further comprising: a firstmembrane disposed between the elastic membrane and the structure; abracket adapted to secure a portion of the first membrane to thestructure; and a fastening means, the fastener being adapted to securelyhold the bracket and the first membrane to the structure.